Integrated circuit package and method

ABSTRACT

In an embodiment, a device includes: an integrated circuit die; an encapsulant at least partially surrounding the integrated circuit die, the encapsulant including fillers having an average diameter; a through via extending through the encapsulant, the through via having a lower portion of a constant width and an upper portion of a continuously decreasing width, a thickness of the upper portion being greater than the average diameter of the fillers; and a redistribution structure including: a dielectric layer on the through via, the encapsulant, and the integrated circuit die; and a metallization pattern having a via portion extending through the dielectric layer and a line portion extending along the dielectric layer, the metallization pattern being electrically coupled to the through via and the integrated circuit die.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a division of U.S. patent application Ser. No.16/427,569 filed on May 31, 2019 and entitled “Integrated CircuitPackage and Method,” which application is hereby incorporated herein byreference.

BACKGROUND

The semiconductor industry has experienced rapid growth due to ongoingimprovements in the integration density of a variety of electroniccomponents (e.g., transistors, diodes, resistors, capacitors, etc.). Forthe most part, improvement in integration density has resulted fromiterative reduction of minimum feature size, which allows morecomponents to be integrated into a given area. As the demand forshrinking electronic devices has grown, a need for smaller and morecreative packaging techniques of semiconductor dies has emerged. Anexample of such packaging systems is Package-on-Package (PoP)technology. In a PoP device, a top semiconductor package is stacked ontop of a bottom semiconductor package to provide a high level ofintegration and component density. PoP technology generally enablesproduction of semiconductor devices with enhanced functionalities andsmall footprints on a printed circuit board (PCB).

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 illustrates a cross-sectional view of an integrated circuit die,in accordance with some embodiments.

FIGS. 2, 3, 4, 5A, 5B, 5C, 5D, 5E, 6, 7, 8A, 8B, 9, 10, 11, 12, 13, 14,15 , and 16 illustrate cross-sectional views of intermediate stepsduring a process for forming a package component, in accordance withsome embodiments.

FIGS. 17 and 18 illustrate formation and implementation of devicestacks, in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the invention. Specificexamples of components and arrangements are described below to simplifythe present disclosure. These are, of course, merely examples and arenot intended to be limiting. For example, the formation of a firstfeature over or on a second feature in the description that follows mayinclude embodiments in which the first and second features are formed indirect contact, and may also include embodiments in which additionalfeatures may be formed between the first and second features, such thatthe first and second features may not be in direct contact. In addition,the present disclosure may repeat reference numerals and/or letters inthe various examples. This repetition is for the purpose of simplicityand clarity and does not in itself dictate a relationship between thevarious embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

In accordance with some embodiments, a package component is formedhaving through vias extending through an encapsulant. The through viasare formed with multiple plating processes of increasing plating currentdensities. As a result of the increasing plating current densities, thethrough vias have tapered upper portions with convex topmost surfacesand continuously decreasing widths. The taper is non-linear. The taperedshapes of the through vias allows defects to be avoided duringsubsequent planarization process(es) for the encapsulant and throughvias.

FIG. 1 illustrates a cross-sectional view of an integrated circuit die50, in accordance with some embodiments. The integrated circuit die 50will be packaged in subsequent processing to form an integrated circuitpackage. The integrated circuit die 50 may be a logic die (e.g., centralprocessing unit (CPU), graphics processing unit (GPU), system-on-a-chip(SoC), application processor (AP), microcontroller, etc.), a memory die(e.g., dynamic random access memory (DRAM) die, static random accessmemory (SRAM) die, etc.), a power management die (e.g., power managementintegrated circuit (PMIC) die), a radio frequency (RF) die, a sensordie, a micro-electro-mechanical-system (MEMS) die, a signal processingdie (e.g., digital signal processing (DSP) die), a front-end die (e.g.,analog front-end (AFE) dies), the like, or combinations thereof.

The integrated circuit die 50 may be formed in a wafer, which mayinclude different device regions that are singulated in subsequent stepsto form a plurality of integrated circuit dies. The integrated circuitdie 50 may be processed according to applicable manufacturing processesto form integrated circuits. For example, the integrated circuit die 50includes a semiconductor substrate 52, such as silicon, doped orundoped, or an active layer of a semiconductor-on-insulator (SOI)substrate. The semiconductor substrate 52 may include othersemiconductor materials, such as germanium; a compound semiconductorincluding silicon carbide, gallium arsenic, gallium phosphide, indiumphosphide, indium arsenide, and/or indium antimonide; an alloysemiconductor including SiGe, GaAsP, AlInAs, AlGaAs, GaInAs, GaInP,and/or GaInAsP; or combinations thereof. Other substrates, such asmulti-layered or gradient substrates, may also be used. Thesemiconductor substrate 52 has an active surface (e.g., the surfacefacing upwards in FIG. 1 ), sometimes called a front side, and aninactive surface (e.g., the surface facing downwards in FIG. 1 ),sometimes called a back side.

Devices 54 may be formed at the front surface of the semiconductorsubstrate 52. The devices 54 may be active devices (e.g., transistors,diodes, etc.), capacitors, resistors, etc. An inter-layer dielectric(ILD) 56 is over the front surface of the semiconductor substrate 52.The ILD 56 surrounds and may cover the devices 54. The ILD 56 mayinclude one or more dielectric layers formed of materials such asPhospho-Silicate Glass (PSG), Boro-Silicate Glass (BSG), Boron-DopedPhospho-Silicate Glass (BPSG), undoped Silicate Glass (USG), or thelike.

Conductive plugs 58 extend through the ILD 56 to electrically andphysically couple the devices 54. For example, when the devices 54 aretransistors, the conductive plugs 58 may couple the gates andsource/drain regions of the transistors. The conductive plugs 58 may beformed of tungsten, cobalt, nickel, copper, silver, gold, aluminum, thelike, or combinations thereof. An interconnect structure 60 is over theILD 56 and conductive plugs 58. The interconnect structure 60interconnects the devices 54 to form an integrated circuit. Theinterconnect structure 60 may be formed by, for example, metallizationpatterns in dielectric layers on the ILD 56. The metallization patternsinclude metal lines and vias formed in one or more low-k dielectriclayers. The metallization patterns of the interconnect structure 60 areelectrically coupled to the devices 54 by the conductive plugs 58.

The integrated circuit die 50 further includes pads 62, such as aluminumpads, to which external connections are made. The pads 62 are on theactive side of the integrated circuit die 50, such as in and/or on theinterconnect structure 60. One or more passivation films 64 are on theintegrated circuit die 50, such as on portions of the interconnectstructure 60 and pads 62. Openings extend through the passivation films64 to the pads 62. Die connectors 66, such as conductive pillars (forexample, formed of a metal such as copper), extend through the openingsin the passivation films 64 and are physically and electrically coupledto respective ones of the pads 62. The die connectors 66 may be formedby, for example, plating, or the like. The die connectors 66electrically couple the respective integrated circuits of the integratedcircuit die 50.

Optionally, solder regions (e.g., solder balls or solder bumps) may bedisposed on the pads 62. The solder balls may be used to perform chipprobe (CP) testing on the integrated circuit die 50. CP testing may beperformed on the integrated circuit die 50 to ascertain whether theintegrated circuit die 50 is a known good die (KGD). Thus, onlyintegrated circuit dies 50, which are KGDs, undergo subsequentprocessing are packaged, and integrated circuit dies 50 which fail theCP testing are not packaged. After testing, the solder regions may beremoved in subsequent processing steps.

A dielectric layer 68 may (or may not) be on the active side of theintegrated circuit die 50, such as on the passivation films 64 and thedie connectors 66. The dielectric layer 68 laterally encapsulates thedie connectors 66, and the dielectric layer 68 is laterally coterminouswith the integrated circuit die 50. Initially, the dielectric layer 68may bury the die connectors 66, such that the topmost surface of thedielectric layer 68 is above the topmost surfaces of the die connectors66. In some embodiments where solder regions are disposed on the dieconnectors 66, the dielectric layer 68 may also bury the solder regions.Alternatively, the solder regions may be removed prior to forming thedielectric layer 68.

The dielectric layer 68 may be a polymer such as PBO, polyimide, BCB, orthe like; a nitride such as silicon nitride or the like; an oxide suchas silicon oxide, PSG, BSG, BPSG, or the like; the like, or acombination thereof. The dielectric layer 68 may be formed, for example,by spin coating, lamination, chemical vapor deposition (CVD), or thelike. In some embodiments, the die connectors 66 are exposed through thedielectric layer 68 during formation of the integrated circuit die 50.In some embodiments, the die connectors 66 remain buried and are exposedduring a subsequent process for packaging the integrated circuit die 50.Exposing the die connectors 66 may remove any solder regions that may bepresent on the die connectors 66.

In some embodiments, the integrated circuit die 50 is a stacked devicethat includes multiple semiconductor substrates 52. For example, theintegrated circuit die 50 may be a memory device such as a hybrid memorycube (HMC) module, a high bandwidth memory (HBM) module, or the likethat includes multiple memory dies. In such embodiments, the integratedcircuit die 50 includes multiple semiconductor substrates 52interconnected by through-substrate vias (TSVs). Each of thesemiconductor substrates 52 may (or may not) have an interconnectstructure 60.

FIGS. 2 through 16 illustrate cross-sectional views of intermediatesteps during a process for forming a first package component 100, inaccordance with some embodiments. The first package component 100 hasmultiple package regions, and one or more of the integrated circuit dies50 are packaged to form an integrated circuit package in each of thepackage regions. A first package region 100A and a second package region100B are illustrated, but it should be appreciated that the firstpackage component 100 may have any number of package regions. Afterformation, the integrated circuit packages in each of the packageregions are singulated. The resulting integrated circuit packages mayalso be referred to as integrated fan-out (InFO) packages.

In FIG. 2 , a carrier substrate 102 is provided, and a release layer 104is formed on the carrier substrate 102. The carrier substrate 102 may bea glass carrier substrate, a ceramic carrier substrate, or the like. Thecarrier substrate 102 may be a wafer, such that multiple packages can beformed on the carrier substrate 102 simultaneously. The release layer104 may be formed of a polymer-based material, which may be removedalong with the carrier substrate 102 from the overlying structures thatwill be formed in subsequent steps. In some embodiments, the releaselayer 104 is an epoxy-based thermal-release material, which loses itsadhesive property when heated, such as a light-to-heat-conversion (LTHC)release coating. In other embodiments, the release layer 104 may be anultra-violet (UV) glue, which loses its adhesive property when exposedto UV lights. The release layer 104 may be dispensed as a liquid andcured, may be a laminate film laminated onto the carrier substrate 102,or may be the like. The top surface of the release layer 104 may beleveled and may have a high degree of planarity.

In FIG. 3 , a back-side redistribution structure 106 may be formed onthe release layer 104. In the embodiment shown, the back-sideredistribution structure 106 includes a dielectric layer 108, ametallization pattern 110 (sometimes referred to as redistributionlayers or redistribution lines), and a dielectric layer 112. Theback-side redistribution structure 106 is optional. In some embodiments,a dielectric layer without metallization patterns is formed on therelease layer 104 in lieu of the back-side redistribution structure 106.

The dielectric layer 108 may be formed on the release layer 104. Thebottom surface of the dielectric layer 108 may be in contact with thetop surface of the release layer 104. In some embodiments, thedielectric layer 108 is formed of a polymer, such as polybenzoxazole(PBO), polyimide, benzocyclobutene (BCB), or the like. In otherembodiments, the dielectric layer 108 is formed of a nitride such assilicon nitride; an oxide such as silicon oxide, phosphosilicate glass(PSG), borosilicate glass (BSG), boron-doped phosphosilicate glass(BPSG), or the like; or the like. The dielectric layer 108 may be formedby any acceptable deposition process, such as spin coating, CVD,laminating, the like, or a combination thereof.

The metallization pattern 110 may be formed on the dielectric layer 108.As an example to form metallization pattern 110, a seed layer is formedover the dielectric layer 108. In some embodiments, the seed layer is ametal layer, which may be a single layer or a composite layer comprisinga plurality of sub-layers formed of different materials. In someembodiments, the seed layer comprises a titanium layer and a copperlayer over the titanium layer. The seed layer may be formed using, forexample, physical vapor deposition (PVD) or the like. A photoresist isthen formed and patterned on the seed layer. The photoresist may beformed by spin coating or the like and may be exposed to light forpatterning. The pattern of the photoresist corresponds to themetallization pattern 110. The patterning forms openings through thephotoresist to expose the seed layer. A conductive material is formed inthe openings of the photoresist and on the exposed portions of the seedlayer. The conductive material may be formed by plating, such aselectroplating or electroless plating, or the like. The conductivematerial may comprise a metal, like copper, titanium, tungsten,aluminum, or the like. Then, the photoresist and portions of the seedlayer on which the conductive material is not formed are removed. Thephotoresist may be removed by an acceptable ashing or stripping process,such as using an oxygen plasma or the like. Once the photoresist isremoved, exposed portions of the seed layer are removed, such as byusing an acceptable etching process, such as by wet or dry etching. Theremaining portions of the seed layer and conductive material form themetallization pattern 110.

The dielectric layer 112 may be formed on the metallization pattern 110and the dielectric layer 108. In some embodiments, the dielectric layer112 is formed of a polymer, which may be a photo-sensitive material suchas PBO, polyimide, BCB, or the like, that may be patterned using alithography mask. In other embodiments, the dielectric layer 112 isformed of a nitride such as silicon nitride; an oxide such as siliconoxide, PSG, BSG, BPSG; or the like. The dielectric layer 112 may beformed by spin coating, lamination, CVD, the like, or a combinationthereof. The dielectric layer 112 is then patterned to form openings 114exposing portions of the metallization pattern 110. The patterning maybe formed by an acceptable process, such as by exposing the dielectriclayer 112 to light when the dielectric layer 112 is a photo-sensitivematerial or by etching using, for example, an anisotropic etch. If thedielectric layer 112 is a photo-sensitive material, the dielectric layer112 can be developed after the exposure.

It should be appreciated that the back-side redistribution structure 106may include any number of dielectric layers and metallization patterns.If more dielectric layers and metallization patterns are to be formed,steps and processes discussed above may be repeated. The metallizationpatterns may include conductive lines and conductive vias. Theconductive vias may be formed during the formation of the metallizationpattern by forming the seed layer and conductive material of themetallization pattern in the opening of the underlying dielectric layer.The conductive vias may therefore interconnect and electrically couplethe various conductive lines.

In FIG. 4 , through vias 116 are formed in the openings 114 andextending away from the topmost dielectric layer of the back-sideredistribution structure 106 (e.g., the dielectric layer 112). Thethrough vias 116 physically and electrically couple the conductivefeatures of the back-side redistribution structure 106, such as themetallization pattern 110. As discussed further below, the through vias116 have upper widths that taper to form convex (e.g., non-flat ordomed) topmost surfaces, which helps avoid defects during subsequentplanarization process(es). The through vias 116 each comprise a seedlayer and multiple layers of a conductive material. FIGS. 5A through 5Eillustrate cross-sectional views of intermediate steps during a processfor forming the through vias 116, in accordance with some embodiments.In particular, a region 5 in FIG. 4 is shown in more detail. Althoughthe formation of a single through via 116 is illustrated, it should beappreciated that multiple through vias 116 are simultaneously formed.

In FIG. 5A, a seed layer 116A is formed over the back-sideredistribution structure 106, e.g., on the dielectric layer 112 andportions of the metallization pattern 110 exposed by the openings 114.In some embodiments, the seed layer 116A is a metal layer, which may bea single layer or a composite layer comprising a plurality of sub-layersformed of different materials. In a particular embodiment, the seedlayer 116A comprises a titanium layer and a copper layer over thetitanium layer. The seed layer 116A may be formed using, for example,PVD or the like. The seed layer 116A is formed to a thickness T₁, whichcan be in the range of about 0.5 μm to about 0.8 μm. A photoresist 118is then formed and patterned on the seed layer 116A. The photoresist 118may be formed by spin coating or the like and may be exposed to lightfor patterning. The pattern of the photoresist 118 corresponds to thethrough vias 116. The patterning forms openings 120 through thephotoresist 118 to expose the seed layer 116A.

In FIG. 5B, a first plating process 122 is performed to form firstconductive material layers 116B in the openings 120 of the photoresist118 and on the exposed portions of the seed layer 116A. The firstconductive material layers 116B may comprise a metal, like copper,titanium, tungsten, aluminum, or the like. The first plating process 122is an electroplating process performed with a first set of platingprocess parameters.

The first plating process 122 is performed using a plating currentdensity small enough so that the respective first conductive materiallayers 116B are plated conformally in the openings 114. For example, theplating current density of the first plating process 122 can be in therange of about 5 A/dm² to about 10 A/dm². Increasing the conformality ofthe first plating process 122 helps the first conductive material layers116B properly adhere to the seed layer 116A, thus reducing the chancesof peeling. For example, when copper is plated, a low initial platingcurrent density allows for a more stable copper-ion deposition rate,which allows for denser first conductive material layers 116B. Theplating current density affects the plating speed, and as such, thefirst plating process 122 has a low plating rate. The first platingprocess 122 is performed until the portions of the first conductivematerial layers 116B outside of the openings 114 are a desired thicknessT₂. For example, the thickness T₂ can be in the range of about 5 μm toabout 10 μm, which can be obtained by performing the first platingprocess 122 for a duration in the range of about 30 seconds to about 90seconds. The thickness T₂ of the first conductive material layers 116Bis greater than the thickness T₁ of the seed layer 116A.

In FIG. 5C, a second plating process 124 is performed to form secondconductive material layers 116C in the openings 120 of the photoresist118 and on the first conductive material layers 116B. The secondconductive material layers 116C may comprise a metal, like copper,titanium, tungsten, aluminum, or the like. In some embodiments, thesecond conductive material layers 116C are the same conductive materialas the first conductive material layers 116B. The second plating process124 is an electroplating process performed with a second set of platingprocess parameters.

The second plating process 124 is performed using a plating currentdensity large enough so that the respective second conductive materiallayers 116C are plated at an acceptable rate. For example, the platingcurrent density of the second plating process 124 can be in the range ofabout 15 A/dm² to about 22 A/dm². Increasing the plating current densityof the second plating process 124 helps the second conductive materiallayers 116C be formed in a low amount of time, reducing themanufacturing costs of the first package component 100. The platingcurrent density affects the plating speed, and as such, the secondplating process 124 has a high plating rate. Notably, the platingcurrent density of the second plating process 124 is greater than theplating current density of the first plating process 122. The secondplating process 124 is performed until the second conductive materiallayers 116C are a desired thickness T₃. For example, the thickness T₃can be in the range of about 150 μm to about 200 μm, which can beobtained by performing the second plating process 124 for a duration inthe range of about 1200 seconds to about 2400 seconds. The thickness T₃of the second conductive material layers 116C is greater than thethickness T₂ of the first conductive material layers 116B and thethickness T₁ of the seed layer 116A.

In FIG. 5D, a third plating process 126 is performed to form thirdconductive material layers 116D in the openings 120 of the photoresist118 and on the second conductive material layers 116C. The thirdconductive material layers 116D may comprise a metal, like copper,titanium, tungsten, aluminum, or the like. In some embodiments, thethird conductive material layers 116D are the same conductive materialas the first conductive material layers 116B and the second conductivematerial layers 116C.

The third plating process 126 is an electroplating process performedwith a third set of plating process parameters. The third platingprocess 126 is performed using a plating current density large enough sothat the respective plated third conductive material layers 116D haveconvex topmost surfaces. For example, the plating current density of thethird plating process 126 can be in the range of about 20 A/dm² to about30 A/dm². Increasing the plating current density of the third platingprocess 126 reduces the plating conformality of the third platingprocess 126. For example, when copper is plated, a high plating currentdensity allows for a greater copper-ion deposition rate, which allowsfor more porous third conductive material layers 116D. The thirdconductive material layers 116D thus have a lesser density than thefirst conductive material layers 116B. The plating current densityaffects the plating speed, and as such, the third plating process 126has a high plating rate. Notably, the plating current density of thethird plating process 126 is greater than the plating current density ofthe second plating process 124. The third plating process 126 isperformed until the third conductive material layers 116D are a desiredthickness T₄. For example, the thickness T₄ can be in the range of about30 μm to about 50 μm, which can be obtained by performing the thirdplating process 126 for a duration in the range of about 900 seconds toabout 1200 seconds. The thickness T₄ of the third conductive materiallayers 116D is less than the thickness T₃ of the second conductivematerial layers 116C, is greater than the thickness T₂ of the firstconductive material layers 116B, and is greater than the thickness T₁ ofthe seed layer 116A.

As a result of the non-conformal third plating process 126, thesidewalls of the third conductive material layers 116D taper to meet thetopmost surfaces of the third conductive material layers 116D. Thewidths of the through vias 116 decrease continuously and non-linearly ina direction extending from the bottoms of the third conductive materiallayers 116D to the topmost surfaces of the third conductive materiallayers 116D, thus forming convex topmost surfaces. In some embodiments,all of the sidewalls of the third conductive material layers 116D aretapered. In some embodiments, only some portions of the sidewalls of thethird conductive material layers 116D are tapered, and remainingportions of the sidewalls of the third conductive material layers 116Dare straight. As discussed below, forming the third conductive materiallayers 116D with convex topmost surfaces helps avoid defects duringsubsequent planarization process(es).

In some embodiments, the first package component 100 is not level duringthe third plating process 126. For example, during the third platingprocess 126, the first package component 100 may be submerged in theplating solution from one side, e.g., with the carrier substrate 102vertically oriented. Due to gravitational forces, the third conductivematerial layers 116D may be asymmetrically plated, e.g., may be platedat different rates. In particular, after submersion, some corner regions116R₁ face towards the ground (e.g., in the direction of gravitationalforces), and opposing corner regions 116R₂ face away from the ground(e.g., away from the direction of gravitational forces). More conductivematerial may be plated in the corner regions 116R₁ facing the groundthan in the corner regions 116R₂ facing away from the ground. Duringplating, copper ions concentrate in the direction of gravitation forces,e.g., in the corner regions 116R₁ facing the ground. When additionalcopper ions are formed during plating, they are attracted to theexisting copper ions in the corner regions 116R₁. Thus, the cornerregions 116R₁ facing the ground may thus have a less rounded profilethan the corner regions 116R₂ facing away from the ground.

In FIG. 5E, the photoresist 118 and portions of the seed layer 116A onwhich the conductive material is not formed are removed. The photoresist118 may be removed by an acceptable ashing or stripping process, such asusing an oxygen plasma or the like. Once the photoresist 118 is removed,exposed portions of the seed layer 116A are removed, such as by using anacceptable etching process, such as by wet or dry etching. The remainingportions of the seed layer 116A and the conductive material layers 116B,116C, and 116D (see FIG. 5D) form the through vias 116. The resultingthrough vias 116 have lower portions 116 _(L) with straight sidewallshaving constant widths W₁, and tapered upper portions 116 _(U) withcontinuously and non-linearly decreasing widths W₂. In other words, theupper portions 116 _(U) have non-linear tapers. The widths W₁ can be inthe range of about 150 μm to about 240 μm. Likewise, the widths W₂ candecrease in a non-linear manner from the width W₁ to a width ofsubstantially nothing at the apexes of the through vias 116. The taperedupper portions 116 _(U) are formed from some or all of the thirdconductive material layers 116D (see FIG. 5D).

In FIG. 6 , integrated circuit dies 50 are adhered to the dielectriclayer 112 by an adhesive 128. A desired type and quantity of integratedcircuit dies 50 are adhered in each of the package regions 100A and100B. In the embodiment shown, multiple integrated circuit dies 50 areadhered adjacent one another, including a first integrated circuit die50A and a second integrated circuit die 50B. The first integratedcircuit die 50A may be a logic device, such as a central processing unit(CPU), graphics processing unit (GPU), system-on-a-chip (SoC),microcontroller, or the like. The second integrated circuit die 50B maybe a memory device, such as a dynamic random access memory (DRAM) die,static random access memory (SRAM) die, hybrid memory cube (HMC) module,a high bandwidth memory (HBM) module, or the like. In some embodiments,the integrated circuit dies 50A and 50B may be the same type of dies,such as SoC dies. The first integrated circuit die 50A and secondintegrated circuit die 50B may be formed in processes of a sametechnology node, or may be formed in processes of different technologynodes. For example, the first integrated circuit die 50A may be of amore advanced process node than the second integrated circuit die 50B.The integrated circuit dies 50A and 50B may have different sizes (e.g.,different heights and/or surface areas), or may have the same size(e.g., same heights and/or surface areas). The space available for thethrough vias 116 in the package regions 100A and 100B may be limited,particularly when the integrated circuit dies 50A and 50B includedevices with a large footprint, such as SoCs. Use of the back-sideredistribution structure 106 allows for an improved interconnectarrangement when the package regions 100A and 100B have limited spaceavailable for the through vias 116.

The adhesive 128 is on back-sides of the integrated circuit dies 50A and50B and adheres the integrated circuit dies 50A and 50B to the back-sideredistribution structure 106, such as to the dielectric layer 112. Theadhesive 128 may be any suitable adhesive, epoxy, die attach film (DAF),or the like. The adhesive 128 may be applied to back-sides of theintegrated circuit dies 50A and 50B or may be applied over the surfaceof the carrier substrate 102. For example, the adhesive 128 may beapplied to the back-sides of the integrated circuit dies 50A and 50Bbefore singulating to separate the integrated circuit dies 50A and 50B.

In FIG. 7 , an encapsulant 130 is formed on and around the variouscomponents. After formation, the encapsulant 130 encapsulates thethrough vias 116 and integrated circuit dies 50. FIG. 8A through 8Billustrate cross-sectional views of intermediate steps during a processfor forming the encapsulant 130, in accordance with some embodiments. Inparticular, a region 8 in FIG. 7 is shown in more detail.

In FIG. 8A, the encapsulant 130 is applied. The encapsulant 130 may be amolding compound, epoxy, or the like. The encapsulant 130 is applied bycompression molding, transfer molding, or the like, and is formed overthe carrier substrate 102 such that the through vias 116 and/or theintegrated circuit dies 50 are buried or covered. The encapsulant 130 isfurther formed in gap regions between the integrated circuit dies 50, ifpresent. The encapsulant 130 may be applied in liquid or semi-liquidform and then subsequently cured.

The encapsulant 130 has accelerators 132 and fillers 134 dispersedtherein. The accelerators 132 comprise a catalyst to accelerate thecuring of the encapsulant 130, such as particles of an organophosphine.Other accelerators may also be used, such as particles of imidazole, anamine, urea derivatives, or Lewis bases and their organic salts. Thefillers 134 comprise a material that provides mechanical strength andthermal dispersion for the encapsulant 130, such as particles of silica(SiO₂). The fillers 134 have a diameter D₁, which can be in the range ofabout 5 μm to about 25 μm. The fillers 134 may not all have identicaldiameters, but may have an average diameter D₁. For example, the averagediameter D₁ can be about 8 μm. Likewise, the accelerators 132 have adiameter D₂, which can be in the range of about 5 μm to about 30 μm. Theaccelerators 132 may not all have identical diameters, but may have anaverage diameter D₂. For example, the average diameter D₂ can be about10 μm. The average diameter D₂ of the accelerators 132 may be greaterthan the average diameter D₁ of the fillers 134.

In FIG. 8B, a planarization process is performed on the encapsulant 130to expose the through vias 116 and the die connectors 66. Theplanarization process also removes material of the through vias 116,dielectric layer 68, and/or die connectors 66 until the die connectors66 and through vias 116 are exposed. Topmost surfaces of the throughvias 116, die connectors 66, dielectric layer 68, and encapsulant 130are coplanar after the planarization process. The planarization processmay be, for example, a chemical-mechanical polish (CMP).

During the CMP, the die connectors 66, dielectric layer 68, through vias116, encapsulant 130, accelerators 132, and fillers 134 are ground by apolishing pad 136 applied with a downward force. Because the encapsulant130 and through vias 116 are formed from differing materials, thedownward force of the polishing pad 136 may be unevenly distributedacross the ground surfaces. For example, dishing may occur such thatsurfaces of the encapsulant 130 are ground further than surfaces of thethrough vias 116. Due to dishing, portions of the encapsulant 130proximate the through vias 116 may be ground with a greater downwardforce than portions of the encapsulant 130 distal the through vias 116.Such an uneven force distribution can cause ground fillers 134 proximatethe through vias 116 to be dug out of the encapsulant 130. For example,ground fillers 134 within a distance of about 2 μm to about 25 μm of thethrough vias 116 may be dug out when the CMP is performed with an unevenforce distribution. When fillers 134 are dug out, voids are formed inthe encapsulant 130, reducing the mechanical stability of the firstpackage component 100. The convex topmost surfaces and tapering widthsof the upper portions 116 _(U) of the through vias 116 reduce the amountof conductive material ground during the CMP, thus reducing dishing andhelping redistribute forces applied to the ground surface of theencapsulant 130 during the CMP, thereby causing the downward force ofthe polishing pad 136 to be more evenly distributed across the groundsurfaces during the CMP. As such, the formation of voids in theencapsulant 130 may be reduced or avoided. During the CMP, the upperportions 116 _(U) of the through vias 116 are ground such that they arereduced to a thickness T₅. The remaining thickness T₅ is greater than 0μm and is less than the original thickness T₄. For example, theremaining thickness T₅ can be in the range of about 8 μm to about 10 μm.Notably, the remaining thickness T₅ is greater than the average diameterD₁ of the fillers 134. A majority of the fillers 134 may thus remainburied during the CMP, thus reducing the exposed surface area of thefillers 134, which may help reduce the amount of fillers 134 that aredug out by the CMP. The lower portions 116 _(L) of the through vias 116are not ground during the CMP. For example, the grinding depth of theCMP may be selected based on the plating process parameters for thethrough vias 116 so that over-grinding is avoided.

When the through vias 116 are ground by the polishing pad 136, residualconductive material 138 is formed. Because the ground fillers 134proximate the through vias 116 remain and are not dug out, the residualconductive material 138 may be removed by the polishing pad, instead ofbeing collected in voids. As discussed further below, shorting of thethrough vias 116 may thus be avoided.

In FIGS. 9 through 12 , a front-side redistribution structure 140 (seeFIG. 12 ) is formed over the encapsulant 130, through vias 116, andintegrated circuit dies 50. The front-side redistribution structure 140includes dielectric layers 142, 146, 150, and 154; and metallizationpatterns 144, 148, and 152. The metallization patterns may also bereferred to as redistribution layers or redistribution lines. Thefront-side redistribution structure 140 is shown as an example havingthree layers of metallization patterns. More or fewer dielectric layersand metallization patterns may be formed in the front-sideredistribution structure 140. If fewer dielectric layers andmetallization patterns are to be formed, steps and process discussedbelow may be omitted. If more dielectric layers and metallizationpatterns are to be formed, steps and processes discussed below may berepeated.

In FIG. 9 , the dielectric layer 142 is deposited on the encapsulant130, through vias 116, and die connectors 66. In some embodiments, thedielectric layer 142 is formed of a photo-sensitive material such asPBO, polyimide, BCB, or the like, which may be patterned using alithography mask. The dielectric layer 142 may be formed by spincoating, lamination, CVD, the like, or a combination thereof. Thedielectric layer 142 is then patterned. The patterning forms openingsexposing portions of the through vias 116 and the die connectors 66. Thepatterning may be by an acceptable process, such as by exposing thedielectric layer 142 to light when the dielectric layer 142 is aphoto-sensitive material or by etching using, for example, ananisotropic etch. If the dielectric layer 142 is a photo-sensitivematerial, the dielectric layer 142 can be developed after the exposure.

The metallization pattern 144 is then formed. The metallization pattern144 includes line portions (also referred to as conductive lines) on andextending along the major surface of the dielectric layer 142. Themetallization pattern 144 further includes via portions (also referredto as conductive vias) extending through the dielectric layer 142 tophysically and electrically couple the through vias 116 and theintegrated circuit dies 50. As an example to form the metallizationpattern 144, a seed layer is formed over the dielectric layer 142 and inthe openings extending through the dielectric layer 142. In someembodiments, the seed layer is a metal layer, which may be a singlelayer or a composite layer comprising a plurality of sub-layers formedof different materials. In some embodiments, the seed layer comprises atitanium layer and a copper layer over the titanium layer. The seedlayer may be formed using, for example, PVD or the like. A photoresistis then formed and patterned on the seed layer. The photoresist may beformed by spin coating or the like and may be exposed to light forpatterning. The pattern of the photoresist corresponds to themetallization pattern 144. The patterning forms openings through thephotoresist to expose the seed layer. A conductive material is thenformed in the openings of the photoresist and on the exposed portions ofthe seed layer. The conductive material may be formed by plating, suchas electroplating or electroless plating, or the like. The conductivematerial may comprise a metal, like copper, titanium, tungsten,aluminum, or the like. The combination of the conductive material andunderlying portions of the seed layer form the metallization pattern144. The photoresist and portions of the seed layer on which theconductive material is not formed are removed. The photoresist may beremoved by an acceptable ashing or stripping process, such as using anoxygen plasma or the like. Once the photoresist is removed, exposedportions of the seed layer are removed, such as by using an acceptableetching process, such as by wet or dry etching.

As noted above, the residual conductive material 138 (see FIG. 8B) fromthe ground through vias 116 may collect in voids formed in theencapsulant 130 during planarization. The residual conductive material138 is large enough to penetrate through the dielectric layer 142, e.g.,the length of the residual conductive material 138 may exceed thethickness of the dielectric layer 142. The residual conductive material138 that penetrates the dielectric layer 142 may electrically bridge thethrough vias 116 to undesired features of the metallization pattern 144.Avoiding the formation of voids in the encapsulant 130 reduces theamount of residual conductive material 138 remaining beneath thedielectric layer 142, and may thus reduce the chances of shorting thethrough vias 116, improving the manufacturing yield for the firstpackage component 100.

In FIG. 10 , the dielectric layer 146 is deposited on the metallizationpattern 144 and dielectric layer 142. The dielectric layer 146 may beformed in a manner similar to the dielectric layer 142, and may beformed of a similar material as the dielectric layer 142.

The metallization pattern 148 is then formed. The metallization pattern148 includes line portions on and extending along the major surface ofthe dielectric layer 146. The metallization pattern 148 further includesvia portions extending through the dielectric layer 146 to physicallyand electrically couple the metallization pattern 144. The metallizationpattern 148 may be formed in a similar manner and of a similar materialas the metallization pattern 144. In some embodiments, the metallizationpattern 148 has a different size than the metallization pattern 144. Forexample, the conductive lines and/or vias of the metallization pattern148 may be wider or thicker than the conductive lines and/or vias of themetallization pattern 144. Further, the metallization pattern 148 may beformed to a greater pitch than the metallization pattern 144.

In FIG. 11 , the dielectric layer 150 is deposited on the metallizationpattern 148 and dielectric layer 146. The dielectric layer 150 may beformed in a manner similar to the dielectric layer 142, and may beformed of a similar material as the dielectric layer 142.

The metallization pattern 152 is then formed. The metallization pattern152 includes line portions on and extending along the major surface ofthe dielectric layer 150. The metallization pattern 152 further includesvia portions extending through the dielectric layer 150 to physicallyand electrically couple the metallization pattern 148. The metallizationpattern 152 may be formed in a similar manner and of a similar materialas the metallization pattern 144. The metallization pattern 152 is thetopmost metallization pattern of the front-side redistribution structure140. As such, all of the intermediate metallization patterns of thefront-side redistribution structure 140 (e.g., the metallizationpatterns 144 and 148) are disposed between the metallization pattern 152and the integrated circuit dies 50. In some embodiments, themetallization pattern 152 has a different size than the metallizationpatterns 144 and 148. For example, the conductive lines and/or vias ofthe metallization pattern 152 may be wider or thicker than theconductive lines and/or vias of the metallization patterns 144 and 148.Further, the metallization pattern 152 may be formed to a greater pitchthan the metallization pattern 148.

In FIG. 12 , the dielectric layer 154 is deposited on the metallizationpattern 152 and dielectric layer 150. The dielectric layer 154 may beformed in a manner similar to the dielectric layer 142, and may beformed of the same material as the dielectric layer 142. The dielectriclayer 154 is the topmost dielectric layer of the front-sideredistribution structure 140. As such, all of the metallization patternsof the front-side redistribution structure 140 (e.g., the metallizationpatterns 144, 148, and 152) are disposed between the dielectric layer154 and the integrated circuit dies 50. Further, all of the intermediatedielectric layers of the front-side redistribution structure 140 (e.g.,the dielectric layers 142, 146, 150) are disposed between the dielectriclayer 154 and the integrated circuit dies 50.

In FIG. 13 , under-bump metallurgies (UBMs) 156 are formed for externalconnection to the front-side redistribution structure 140. The UBMs 156have bump portions on and extending along the major surface of thedielectric layer 154, and have via portions extending through thedielectric layer 154 to physically and electrically couple themetallization pattern 152. As a result, the UBMs 156 are electricallycoupled to the through vias 116 and the integrated circuit dies 50. TheUBMs 156 may be formed of the same material as the metallization pattern144. In some embodiments, the UBMs 156 has a different size than themetallization patterns 144, 148, and 152.

In FIG. 14 , conductive connectors 158 are formed on the UBMs 156. Theconductive connectors 158 may be ball grid array (BGA) connectors,solder balls, metal pillars, controlled collapse chip connection (C4)bumps, micro bumps, electroless nickel-electroless palladium-immersiongold technique (ENEPIG) formed bumps, or the like. The conductiveconnectors 158 may include a conductive material such as solder, copper,aluminum, gold, nickel, silver, palladium, tin, the like, or acombination thereof. In some embodiments, the conductive connectors 158are formed by initially forming a layer of solder through evaporation,electroplating, printing, solder transfer, ball placement, or the like.Once a layer of solder has been formed on the structure, a reflow may beperformed in order to shape the material into the desired bump shapes.In another embodiment, the conductive connectors 158 comprise metalpillars (such as a copper pillar) formed by a sputtering, printing,electro plating, electroless plating, CVD, or the like. The metalpillars may be solder free and have substantially vertical sidewalls. Insome embodiments, a metal cap layer is formed on the top of the metalpillars. The metal cap layer may include nickel, tin, tin-lead, gold,silver, palladium, indium, nickel-palladium-gold, nickel-gold, the like,or a combination thereof and may be formed by a plating process.

In FIG. 15 , a carrier substrate de-bonding is performed to detach (or“de-bond”) the carrier substrate 102 from the back-side redistributionstructure 106, e.g., the dielectric layer 108. In accordance with someembodiments, the de-bonding includes projecting a light such as a laserlight or an UV light on the release layer 104 so that the release layer104 decomposes under the heat of the light and the carrier substrate 102can be removed. The structure is then flipped over and placed on a tape.

In FIG. 16 , conductive connectors 160 are formed extending through thedielectric layer 108 to contact the metallization pattern 110. Openingsare formed through the dielectric layer 108 to expose portions of themetallization pattern 110. The openings may be formed, for example,using laser drilling, etching, or the like. The conductive connectors160 are formed in the openings. In some embodiments, the conductiveconnectors 160 comprise flux and are formed in a flux dipping process.In some embodiments, the conductive connectors 160 comprise a conductivepaste such as solder paste, silver paste, or the like, and are dispensedin a printing process. In some embodiments, the conductive connectors160 are formed in a manner similar to the conductive connectors 158, andmay be formed of a similar material as the conductive connectors 158.

FIGS. 17 and 18 illustrate formation and implementation of devicestacks, in accordance with some embodiments. The device stacks areformed from the integrated circuit packages formed in the first packagecomponent 100. The device stacks may also be referred to aspackage-on-package (PoP) structures.

In FIG. 17 , second package components 200 are coupled to the firstpackage component 100. One of the second package components 200 arecoupled in each of the package regions 100A and 100B to form anintegrated circuit device stack in each region of the first packagecomponent 100.

The second package components 200 include a substrate 202 and one ormore dies coupled to the substrate 202. In the illustrated embodiment,the dies include stacked dies 204A and 204B. In some embodiments, thedies (or die stacks) may be disposed side-by-side coupled to a samesurface of the substrate 202. The substrate 202 may be made of asemiconductor material such as silicon, germanium, diamond, or the like.In some embodiments, compound materials such as silicon germanium,silicon carbide, gallium arsenic, indium arsenide, indium phosphide,silicon germanium carbide, gallium arsenic phosphide, gallium indiumphosphide, combinations of these, and the like, may also be used.Additionally, the substrate 202 may be a silicon-on-insulator (SOI)substrate. Generally, an SOI substrate includes a layer of asemiconductor material such as epitaxial silicon, germanium, silicongermanium, SOI, silicon germanium on insulator (SGOI), or combinationsthereof. The substrate 202 is, in one alternative embodiment, based onan insulating core such as a fiberglass reinforced resin core. Oneexample core material is fiberglass resin such as FR4. Alternatives forthe core material include bismaleimide-triazine (BT) resin, oralternatively, other printed circuit board (PCB) materials or films.Build up films such as Ajinomoto build-up film (ABF) or other laminatesmay be used for substrate 202.

The substrate 202 may include active and passive devices (not shown). Awide variety of devices such as transistors, capacitors, resistors,combinations of these, and the like may be used to generate thestructural and functional requirements of the design for the secondpackage components 200. The devices may be formed using any suitablemethods.

The substrate 202 may also include metallization layers (not shown) andconductive vias 206. The metallization layers may be formed over theactive and passive devices and are designed to connect the variousdevices to form functional circuitry. The metallization layers may beformed of alternating layers of dielectric (e.g., low-k dielectricmaterial) and conductive material (e.g., copper) with viasinterconnecting the layers of conductive material and may be formedthrough any suitable process (such as deposition, damascene, dualdamascene, or the like). In some embodiments, the substrate 202 issubstantially free of active and passive devices.

The substrate 202 may have bond pads 208 on a first side of thesubstrate 202 to couple to the stacked dies 204A and 204B, and bond pads210 on a second side of the substrate 202, the second side beingopposite the first side of the substrate 202, to couple to theconductive connectors 160. In some embodiments, the bond pads 208 and210 are formed by forming recesses into dielectric layers on the firstand second sides of the substrate 202. The recesses may be formed toallow the bond pads 208 and 210 to be embedded into the dielectriclayers. In other embodiments, the recesses are omitted as the bond pads208 and 210 may be formed on the dielectric layer. In some embodiments,the bond pads 208 and 210 include a thin seed layer made of copper,titanium, nickel, gold, palladium, the like, or a combination thereof.The conductive material of the bond pads 208 and 210 may be depositedover the thin seed layer. The conductive material may be formed by anelectro-chemical plating process, an electroless plating process, CVD,atomic layer deposition (ALD), PVD, the like, or a combination thereof.In an embodiment, the conductive material of the bond pads 208 and 210is copper, tungsten, aluminum, silver, gold, the like, or a combinationthereof.

In an embodiment, the bond pads 208 and 210 are UBMs that include threelayers of conductive materials, such as a layer of titanium, a layer ofcopper, and a layer of nickel. Other arrangements of materials andlayers, such as an arrangement of chrome/chrome-copperalloy/copper/gold, an arrangement of titanium/titanium tungsten/copper,or an arrangement of copper/nickel/gold, may be utilized for theformation of the bond pads 208 and 210. Any suitable materials or layersof material that may be used for the bond pads 208 and 210 are fullyintended to be included within the scope of the current application. Insome embodiments, the conductive vias 206 extend through the substrate202 and couple at least one of the bond pads 208 to at least one of thebond pads 210.

In the illustrated embodiment, the stacked dies 204A and 204B arecoupled to the substrate 202 by wire bonds 212, although otherconnections may be used, such as conductive bumps. In an embodiment, thestacked dies 204A and 204B are stacked memory dies. For example, thestacked dies 204A and 204B may be memory dies such as low-power (LP)double data rate (DDR) memory modules, such as LPDDR1, LPDDR2, LPDDR3,LPDDR4, or the like memory modules.

The stacked dies 204A and 204B and the wire bonds 212 may beencapsulated by a molding material 214. The molding material 214 may bemolded on the stacked dies 204A and 204B and the wire bonds 212, forexample, using compression molding. In some embodiments, the moldingmaterial 214 is a molding compound, a polymer, an epoxy, silicon oxidefiller material, the like, or a combination thereof. A curing processmay be performed to cure the molding material 214; the curing processmay be a thermal curing, a UV curing, the like, or a combinationthereof.

In some embodiments, the stacked dies 204A and 204B and the wire bonds212 are buried in the molding material 214, and after the curing of themolding material 214, a planarization step, such as a grinding, isperformed to remove excess portions of the molding material 214 andprovide a substantially planar surface for the second package components200.

After the second package components 200 are formed, the second packagecomponents 200 are mechanically and electrically bonded to the firstpackage component 100 by way of the conductive connectors 160, the bondpads 208 and 210, and a metallization pattern of the back-sideredistribution structure 106. In some embodiments, the stacked dies 204Aand 204B may be coupled to the integrated circuit dies 50 through thewire bonds 212, the bond pads 208 and 210, conductive vias 206, theconductive connectors 160, the back-side redistribution structure 106,the through vias 116, and the front-side redistribution structure 140.

In some embodiments, a solder resist is formed on the side of thesubstrate 202 opposing the stacked dies 204A and 204B. The conductiveconnectors 160 may be disposed in openings in the solder resist to beelectrically and mechanically coupled to conductive features (e.g., thebond pads 210) in the substrate 202. The solder resist may be used toprotect areas of the substrate 202 from external damage.

In some embodiments, the conductive connectors 160 have an epoxy fluxformed thereon before they are reflowed with at least some of the epoxyportion of the epoxy flux remaining after the second package components200 are attached to the first package component 100.

In some embodiments, an underfill is formed between the first packagecomponent 100 and the second package components 200, surrounding theconductive connectors 160. The underfill may reduce stress and protectthe joints resulting from the reflowing of the conductive connectors160. The underfill may be formed by a capillary flow process after thesecond package components 200 are attached, or may be formed by asuitable deposition method before the second package components 200 areattached. In embodiments where the epoxy flux is formed, it may act asthe underfill.

In FIG. 18 , a singulation process is performed by sawing along scribeline regions, e.g., between the first package region 100A and the secondpackage region 100B. The sawing singulates the first package region 100Afrom the second package region 100B. The resulting, singulated devicestack is from one of the first package region 100A or the second packageregion 100B. In the illustrated embodiment, the singulation process isperformed after the second package components 200 are coupled to thefirst package component 100. In other embodiments, the singulationprocess is performed before the second package components 200 arecoupled to the first package component 100, such as after the carriersubstrate 102 is de-bonded and the conductive connectors 160 are formed.

Each integrated circuit package singulated from the first packagecomponent 100 is then mounted to a package substrate 300 using theconductive connectors 158. The package substrate 300 includes asubstrate core 302 and bond pads 304 over the substrate core 302. Thesubstrate core 302 may be made of a semiconductor material such assilicon, germanium, diamond, or the like. Alternatively, compoundmaterials such as silicon germanium, silicon carbide, gallium arsenic,indium arsenide, indium phosphide, silicon germanium carbide, galliumarsenic phosphide, gallium indium phosphide, combinations of these, andthe like, may also be used. Additionally, the substrate core 302 may bea SOI substrate. Generally, an SOI substrate includes a layer of asemiconductor material such as epitaxial silicon, germanium, silicongermanium, SOI, SGOI, or combinations thereof. The substrate core 302is, in one alternative embodiment, based on an insulating core such as afiberglass reinforced resin core. One example core material isfiberglass resin such as FR4. Alternatives for the core material includebismaleimide-triazine BT resin, or alternatively, other PCB materials orfilms. Build up films such as ABF or other laminates may be used forsubstrate core 302.

The substrate core 302 may include active and passive devices (notshown). As one of ordinary skill in the art will recognize, a widevariety of devices such as transistors, capacitors, resistors,combinations of these, and the like may be used to generate thestructural and functional requirements of the design for the devicestack. The devices may be formed using any suitable methods.

The substrate core 302 may also include metallization layers and vias(not shown), with the bond pads 304 being physically and/or electricallycoupled to the metallization layers and vias. The metallization layersmay be formed over the active and passive devices and are designed toconnect the various devices to form functional circuitry. Themetallization layers may be formed of alternating layers of dielectric(e.g., low-k dielectric material) and conductive material (e.g., copper)with vias interconnecting the layers of conductive material and may beformed through any suitable process (such as deposition, damascene, dualdamascene, or the like). In some embodiments, the substrate core 302 issubstantially free of active and passive devices.

In some embodiments, the conductive connectors 158 are reflowed toattach the first package component 100 to the bond pads 304. Theconductive connectors 158 electrically and/or physically couple thepackage substrate 300, including metallization layers in the substratecore 302, to the first package component 100. In some embodiments, asolder resist 306 is formed on the substrate core 302. The conductiveconnectors 158 may be disposed in openings in the solder resist 306 tobe electrically and mechanically coupled to the bond pads 304. Thesolder resist 306 may be used to protect areas of the package substrate300 from external damage.

The conductive connectors 158 may have an epoxy flux formed thereonbefore they are reflowed with at least some of the epoxy portion of theepoxy flux remaining after the first package component 100 is attachedto the package substrate 300. This remaining epoxy portion may act as anunderfill to reduce stress and protect the joints resulting from thereflowing the conductive connectors 158. In some embodiments, anunderfill 308 may be formed between the first package component 100 andthe package substrate 300 and surrounding the conductive connectors 158.The underfill 308 may be formed by a capillary flow process after thefirst package component 100 is attached or may be formed by a suitabledeposition method before the first package component 100 is attached.

In some embodiments, passive devices (e.g., surface mount devices(SMDs), not shown) may also be attached to the first package component100 (e.g., to the UBMs 156) or to the package substrate 300 (e.g., tothe bond pads 304). For example, the passive devices may be bonded to asame surface of the first package component 100 or the package substrate300 as the conductive connectors 158. The passive devices may beattached to the first package component 100 prior to mounting the firstpackage component 100 on the package substrate 300, or may be attachedto the package substrate 300 prior to or after mounting the firstpackage component 100 on the package substrate 300.

It should be appreciated that the first package component 100 may beimplement in other device stacks. For example, a PoP structure is shown,but the first package component 100 may also be implemented in a FlipChip Ball Grid Array (FCBGA) package. In such embodiments, the firstpackage component 100 is mounted to a substrate such as the packagesubstrate 300, but the second package component 200 is omitted. Instead,a lid or heat spreader may be attached to the first package component100. When the second package component 200 is omitted, the back-sideredistribution structure 106 and through vias 116 may also be omitted.

Other features and processes may also be included. For example, testingstructures may be included to aid in the verification testing of the 3Dpackaging or 3DIC devices. The testing structures may include, forexample, test pads formed in a redistribution layer or on a substratethat allows the testing of the 3D packaging or 3DIC, the use of probesand/or probe cards, and the like. The verification testing may beperformed on intermediate structures as well as the final structure.Additionally, the structures and methods disclosed herein may be used inconjunction with testing methodologies that incorporate intermediateverification of known good dies to increase the yield and decreasecosts.

Embodiments may achieve advantages. Forming the through vias 116 withthree plating processes 122, 124, and 126 of successively higher platingcurrent densities allows the conformality of the plating processes 122,124, and 126 and the widths W₁ and W₂ (see FIGS. 5B-5E) of the resultingthrough vias 116 to be controlled. Plating the initial layers of thethrough vias 116 (e.g., the first conductive material layers 116B, seeFIG. 5B) with a conformal plating process helps the first conductivematerial layers 116B properly adhere to the seed layer 116A, thusreducing the chances of peeling. Plating the final layers of the throughvias 116 (e.g., the third conductive material layers 116D, see FIG. 5D)with a non-conformal plating process helps the third conductive materiallayers 116D form tapered upper portions 116 _(U) with convex topmostsurfaces and continuously and non-linearly decreasing widths (see FIG.5E). The tapered upper portions 116 _(U) of the through vias 116 helpreduce or avoid the formation of voids in the encapsulant 130 duringplanarization process(es) for the encapsulant 130 (see FIG. 8B). Themechanical stability of the first package component 100 may thus beincreased. Further, the chances of shorting the through vias 116 may bereduced, improving the manufacturing yield for the first packagecomponent 100.

In an embodiment, a device includes: an integrated circuit die; anencapsulant at least partially surrounding the integrated circuit die,the encapsulant including fillers having an average diameter; a throughvia extending through the encapsulant, the through via having a lowerportion of a constant width and an upper portion of a continuouslydecreasing width, a thickness of the upper portion being greater thanthe average diameter of the fillers; and a redistribution structureincluding: a dielectric layer on the through via, the encapsulant, andthe integrated circuit die; and a metallization pattern having a viaportion extending through the dielectric layer and a line portionextending along the dielectric layer, the metallization pattern beingelectrically coupled to the through via and the integrated circuit die.

In some embodiments of the device, the upper portion of the through viahas a non-linear taper in a direction extending from the lower portionof the through via towards the upper portion of the through via. In someembodiments of the device, the thickness of the upper portion of thethrough via is in a range of 8 μm to 10 μm. In some embodiments of thedevice, the upper portion of the through via has first corner regionswith a first rounded profile, and second corner regions with a secondrounded profile, the second rounded profile being different from thefirst rounded profile. In some embodiments of the device, a portion ofthe fillers are disposed within a first distance of the through via, thefirst distance being in a range of 2 μm to 25 μm. In some embodiments ofthe device, the encapsulant further includes accelerators having anaverage diameter, the average diameter of the accelerators being lessthan the average diameter of the fillers. In some embodiments of thedevice, the fillers are silica, and the accelerators are anorganophosphine.

In an embodiment, a method includes: forming a first opening in a firstdielectric layer, the first opening exposing a first metallizationpattern; and forming a through via including: depositing a seed layer inthe first opening and on portions of the first metallization patternexposed by the first opening; plating a first conductive material layeron the seed layer with a first plating process, the first platingprocess being performed with a first plating current density; plating asecond conductive material layer on the first conductive material layerwith a second plating process, the second plating process beingperformed with a second plating current density, the second platingcurrent density being greater than the first plating current density;and plating a third conductive material layer on the second conductivematerial layer with a third plating process, the third plating processbeing performed with a third plating current density, the third platingcurrent density being greater than the second plating current density.

In some embodiments, the method further includes: placing an integratedcircuit die on the first dielectric layer adjacent the through via;encapsulating the integrated circuit die and the through via with anencapsulant; and planarizing the encapsulant such that topmost surfacesof the encapsulant, the integrated circuit die, and the through via arelevel. In some embodiments of the method, the encapsulant includesfillers having an average diameter, where the through via has a lowerportion of a constant width and an upper portion of a continuouslydecreasing width, and where a thickness of the upper portion is greaterthan the average diameter of the fillers after planarizing the throughvia. In some embodiments of the method, the thickness of the upperportion of the through via is in a range of 8 μm to 10 μm. In someembodiments of the method, the encapsulant further includes acceleratorshaving an average diameter, the average diameter of the acceleratorsbeing less than the average diameter of the fillers. In some embodimentsof the method, the fillers are silica, and the accelerators are anorganophosphine. In some embodiments of the method, the first platingcurrent density is in a range of 5 A/dm² to 10 A/dm², the second platingcurrent density is in a range of 15 A/dm² to 22 A/dm², and the thirdplating current density is in a range of 20 A/dm² to 30 A/dm². In someembodiments of the method, a thickness of the second conductive materiallayer is greater than a thickness of the first conductive materiallayer, and where a thickness of the third conductive material layer isless than the thickness of the second conductive material layer. In someembodiments of the method, the seed layer includes a titanium layer, andwhere the first conductive material layer, the second conductivematerial layer, and the third conductive material layer include copperlayers. In some embodiments of the method, plating the third conductivematerial layer includes plating first corner regions of the thirdconductive material layer at a different rate than second corner regionsof the third conductive material layer.

In an embodiment, a method includes: forming a through via extendingfrom a dielectric layer, the through via having a convex topmostsurface, the through via being formed with a plurality of platingprocesses, each successive one of the plating processes being performedat a higher plating current density than a previous one of the platingprocesses; placing an integrated circuit die on the dielectric layeradjacent the through via; encapsulating the integrated circuit die andthe through via with an encapsulant, the encapsulant including fillershaving an average diameter; planarizing the encapsulant such thattopmost surfaces of the encapsulant, the integrated circuit die, and thethrough via are level, where after the planarizing, remaining portionsof the convex topmost surface of the through via having a firstthickness, the first thickness being greater than the average diameterof the fillers; and forming a redistribution structure on the throughvia, the encapsulant, and the integrated circuit die, the redistributionstructure electrically coupling the through via and the integratedcircuit die.

In some embodiments of the method, an initial one of the platingprocesses is a conformal plating process, and a final one of the platingprocesses is a non-conformal plating process. In some embodiments of themethod, the first thickness of the remaining portions of the convextopmost surface is in a range of 8 μm to 10 μm.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A device comprising: an integrated circuit die;an encapsulant at least partially surrounding the integrated circuitdie, the encapsulant comprising fillers having an average diameter; athrough via extending through the encapsulant, the through via having alower portion of a constant width and having an upper portion of acontinuously decreasing width, a thickness of the upper portion beinggreater than the average diameter of the fillers, wherein a conductivematerial of the upper portion of the through via has a lesser densitythan a conductive material of the lower portion of the through via; anda redistribution structure comprising: a dielectric layer on the throughvia, the encapsulant, and the integrated circuit die; and ametallization pattern having a via portion extending through thedielectric layer and having a line portion extending along thedielectric layer, the metallization pattern being electrically coupledto the through via and the integrated circuit die.
 2. The device ofclaim 1, wherein the upper portion of the through via has a non-lineartaper in a direction extending from the lower portion of the through viatowards the upper portion of the through via.
 3. The device of claim 1,wherein the thickness of the upper portion of the through via is in arange of 8 μm to 10 μm.
 4. The device of claim 1, wherein the upperportion of the through via has first corner regions with a first roundedprofile and has second corner regions with a second rounded profile, thesecond rounded profile being different from the first rounded profile.5. The device of claim 1, wherein a portion of the fillers are disposedwithin a first distance of the through via, the first distance being ina range of 2 μm to 25 μm.
 6. The device of claim 1, wherein theencapsulant further comprises accelerators having an average diameter,the average diameter of the accelerators being less than the averagediameter of the fillers.
 7. The device of claim 6, wherein the fillersare silica, and the accelerators are an organophosphine.
 8. The deviceof claim 1, wherein the conductive material of the upper portion of thethrough via is more porous than the conductive material of the lowerportion of the through via.
 9. A device comprising: a firstredistribution structure comprising first redistribution lines; a secondredistribution structure comprising second redistribution lines; anencapsulant between the first redistribution structure and the secondredistribution structure; and a through via extending through theencapsulant, the through via having a first portion proximate the firstredistribution structure and having a second portion proximate thesecond redistribution structure, the first portion having straightsidewalls, the second portion having tapered sidewalls, the through viaconnecting the first redistribution lines of the first redistributionstructure to the second redistribution lines of the secondredistribution structure, wherein a conductive material of the secondportion of the through via has a lesser density than a conductivematerial of the first portion of the through via.
 10. The device ofclaim 9 further comprising: an integrated circuit die in theencapsulant, the integrated circuit die connected to the secondredistribution lines of the second redistribution structure.
 11. Thedevice of claim 9, wherein the second portion of the through via has afirst corner region with a first rounded profile and has a second cornerregion with a second rounded profile, the second rounded profile beingdifferent from the first rounded profile.
 12. The device of claim 9,wherein the encapsulant comprises silica fillers having an averagediameter, and a thickness of the second portion of the through via isgreater than the average diameter of the silica fillers, the thicknessof the second portion of the through via measured in a directionextending from the first portion of the through via towards the secondportion of the through via.
 13. The device of claim 9 furthercomprising: a package substrate; and conductive connectors connectingthe package substrate to the second redistribution lines of the secondredistribution structure.
 14. The device of claim 9, wherein the taperedsidewalls of the second portion of the through via taper non-linearly ina direction extending from the first portion of the through via towardsthe second portion of the through via.
 15. The device of claim 9,wherein the conductive material of the second portion of the through viais the same material as the conductive material of the first portion ofthe through via.
 16. A device comprising: a first metallization pattern;a first dielectric layer on the first metallization pattern; a moldingcompound on the first dielectric layer; a second dielectric layer on themolding compound; a second metallization pattern on the seconddielectric layer; and a through via connecting the second metallizationpattern to the first metallization pattern, the through via having alower portion and an upper portion in the molding compound, the lowerportion adjacent the first dielectric layer, the lower portion having afirst width that is constant, the upper portion adjacent the seconddielectric layer, the upper portion having a second width that decreasesnon-linearly in a direction extending from the lower portion towards theupper portion, wherein the upper portion of the through via has a firstcorner region and a second corner region, the first corner region havinga less rounded profile than the second corner region.
 17. The device ofclaim 16 further comprising: an integrated circuit die in the moldingcompound, the integrated circuit die connected to the secondmetallization pattern.
 18. The device of claim 16, wherein a conductivematerial of the upper portion of the through via has a lesser densitythan a conductive material of the lower portion of the through via. 19.The device of claim 16, wherein the molding compound comprises silicafillers having an average diameter, and a thickness of the upper portionof the through via is greater than the average diameter of the silicafillers, the thickness of the upper portion of the through via measuredin the direction extending from the lower portion towards the upperportion.
 20. The device of claim 19, wherein the thickness of the upperportion of the through via is in a range of 8 μm to 10 μm.